Method for Joining Workpieces Together and Product Made Thereby

ABSTRACT

A method of forming a joint between first and second workpieces generally consisting of forming a recess in one of such workpieces, provided with at least one side wall having a serrated cross-sectional configuration with inwardly projecting, distortable segments; providing a portion in the other of such workpieces, insertable into such recess, having a cross-sectional configuration sufficient to engage and distort such segments as such portion is inserted into such recess; and inserting such portion of the other workpiece into such recess, causing the segments to distort and thus provide an interference fit between such workpieces.

This invention relates to an method of forming a joint between a pair of workpieces, and more particularly to a such a method that does not require the use of clamping devices in positioning and holding such workpieces together, allowing a bonding agent applied to the joint to set. Such invention further contemplates a product formed through the use of such method and a tool functional to configure such workpieces to facilitate the practice of such method.

BACKGROUND OF THE INVENTION

In the manufacture of furniture and other similar products, it is a common practice to utilize mortise and tenon type joints to interconnect various workpieces used to construct a product. The mortise and tenon joint consists of a socket formed in a first workpiece, and a protrusion formed on a second workpiece adapted to be inserted and snuggly fit into the socket or mortise of the first workpiece. In the cabinetmaking industry, the terms mortise and tenon often are used to describe a broad range of joints, utilizing the same method of joining a pair of workpieces. Referring to FIG. 1 of the drawings, a tenon may consists of simply a rabbet formed on the edge of a panel 104 or a tongue formed in the center of an edge of a panel 105. A tenon also may be formed on the end of a style or rail 101. Similarly, a mortise may be a simple pocket cutout 102 or an elongated slot 103 or a groove 103 extending the entire length of a panel. The term tongue and groove sometimes is used to describe the aforementioned type of joint when such joint is used to join large panels in the cabinet industry.

Typically, mortises as well as tenons are formed utilizing various multiple machine operations. One of the problems encountered in the prior art in forming joints is the requirement for clamping mortises together to permit bonding agents used to permanently secure the workpieces together to set. The reliance on clamps for securing such workpieces together presents several major disadvantages. The clamping operation requires the manufacturer to maintain a large inventory of clamps of various sizes to accommodate the many varied work pieces encountered in the course of daily operations. Additionally, a large number of assemblies are generally staged in the clamping process at a given time, awaiting the setting of the bonding agent. Still an additional problem encountered in the prior art is the necessity to provide labor for applying such clamps and subsequently removing them when the bonding agent has cured.

There have been numerous attempts in the prior art to circumvent the clamping operation, including the application of permanent mechanical fasteners such as, small nails or brads. Such an operation is undesirable in the sense that it adds additional labor to the construction of the final product, and may detract from the appearance of the product, weaken the completed joint or possibly even result in damaging the material beyond salvage. Accordingly, it is the principal object of the present invention to provide an improved method of joining a pair of workpieces together in the manufacture of a product which eliminates the requirement of the use of various securing devices such as clamps, fixtures and fasteners such as small nails and brads.

SUMMARY OF THE INVENTION

The principal object of the invention is achieved by providing a method of forming a joint between a pair of workpieces, generally consisting of forming a recess in one of such workpieces, provided with at least one side wall having a serrated cross-sectional configuration with inwardly projecting, distortable segments; providing a portion of the other of such workpieces insertable into the recess of the first workpiece, having a cross-sectional configuration sufficient to engage and distort the inwardly projecting, distortable components of the first member, as such projecting portion is inserted into the recess; and inserting the projecting portion of the other workpiece into such recess causing such segments to distort and thus provide an interference fit between such workpieces. Preferably, a bonding agent is applied to one of the recess and the projecting portion prior to insertion of such portion into the recess of the other workpiece, such distortable segments are provided with sloped surfaces engageable by the insertable portion inserted into the recess of the other workpiece, causing such segments to deflect toward a bottom of the recess and thereby fix the inserted portion within the recess. Such recess may be provided with a circular or polygonal cross-sectional configuration, and the recess one of such workpieces may be provided with a pair of opposed side walls each provided with a serrated cross-sectional configuration, and the insertable portion may be provided with a pair of outer side wall, surfaces cooperable with serrated segments of the opposed side wall surfaces of the recess. The recess in one of such workpieces may consist of a mortise, socket, dados, pocket mortise, slot or grove, and the insertable portion of the other workpiece may consist of a tenon, rabbet or tongue.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a set of perspective views of several combinations of workpieces, illustrating the joining components thereof in exploded relation;

FIG. 2 is a perspective view of a set of components joined together utilizing a clamping device, in the conventional manner;

FIG. 3 is a perspective view of a CNC router which may be utilized to form recesses in workpieces intended to be joined together by use of the claimed method;

FIG. 4 includes a first perspective view of a number of components of a product to be joined together by use of the claimed method, illustrated in exploded relation, and a prospective view of the product formed of the components shown in the other view, secured together by use of the claimed method;

FIG. 5 consists of side, end and prospective views of a tool functional to form a side wall surface of a recess in a workpiece, in accordance with the claimed method;

FIG. 6 includes a pair of top and side views illustrating the manner in which the tool illustrated in FIG. 5 may be utilized to form the contours of the side walls of a recess in a workpiece in accordance with the claimed method;

FIG. 7 is a side elevational view of a pair of workpieces to be joined together utilizing the claimed method, shown in exploded relation; and

FIG. 8 is a side elevational view of the components shown in FIG. 7 joined together through the use of the claimed method.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS OF THE INVENTION

Generally, in the cabinet making trade, machining operations required for making mortise and tenon joints for joining panels together are performed on a CNC router. The various components comprising the main body of a kitchen cabinet, as an example, are generally machined on a flatbed CNC router, from full sized sheets of panel stock. The process also may be carried out using a handheld portable router, or by using ordinary cabinetmakers' hand tools, although the latter is considered more of an art than a craft.

Referring to FIG. 3 of the drawings, in a typical manufacturing environment utilizing a CNC machine 301, components are manufactured by first loading a tool-path program into the machine control 302. Material in the form of full sized sheet stock is then placed upon worktable 302 of the CNC machine. The tool-path program through the computer component of the machine control 302 then guides the tool 304 through multiple program cut paths, producing components that will be configured for assembly into a final product, upon removal from the machine's worktable. FIG. 4 illustrates a set of completed panels 401 and a completed unit 402 assembled from such panels.

Referring to FIG. 5, there is illustrated a cutting tool 501 designed to produce a side wall configuration of a groove, in a workpiece. The tool consists of an elongated cylindrical body, adapted to be inserted into a collet of a machine spindle, and is provided with a plurality of annular recesses at an end thereof and a pair of longitudinally extending, diametrically opposed grooves in the lower circumferential surface thereof cooperating with such annular recesses to provide a cutting tool configuration functional to produce a serrated cutting pattern. Multiple teeth 502 of the tool impart the unique serrated configuration depicted in the side wall of the groove in work piece 602 shown in FIG. 6. The profile of each tooth formed by the plurality of annular recesses is configured in a manner whereby the upper most edge tapers to a point on the outer circumference of the tool. The tool cuts the material in a manner so as to produce tapered projections on the side wall of, a mortise slot.

Referring to FIG. 6, the tool shown in FIG. 5, is designed to cut the mortise in two or more passes as depicted in the diagram identified by the reference numeral 601, providing for chip removal as well as for more finely machining the width of the mortise to a precise dimension. The tool may enter the work piece from an end thereof or it may enter the material through the top surface for producing blind dados or pocket mortises. The tapered side wall projections are best illustrated in the recess formed in workpiece 602 shown in FIG. 6.

FIGS. 6 through 8 illustrate the use of the inventive method in joining a pair of workpieces together. Initially, as shown in FIG. 6, a mortise is formed in one of the workpieces usually by the use of a CNC router as shown in FIG. 3. Once the mortise has been formed, a tool as shown in FIG. 5 is utilized to form a serrated configuration on the side walls of the mortise in workpiece 602 as shown in FIG. 6. Next, as shown in FIG. 7, a bonding agent is applied to mortise 70, tenon 701 of the second workpiece is aligned with mortise 702 provided with serrated side walls 703 and tenon 701 is inserted into mortise 702 to complete the joint as shown in FIG. 8. As tenon 701 is inserted in mortise 702 the inwardly projecting segments of the serrated side wall surfaces of the mortise will be caused to deform and deflect downwardly providing an interference fit of tenon 701 in mortise 702. Such interference fit secures the two workpieces in the desired relationship, allowing the bonding agent to cure and thus permanently secure the two components together in the desired relationship.

To facilitate the insertion of the tenon on one workpiece into the mortise of the other workpiece, the surfaces of the inwardly projecting, segments of the serrated side wall surfaces of the mortise engaged by the tenon are sloped downwardly and inwardly as best shown in FIGS. 6 and 7. Such sloped surfaces are provided by forming the annular recesses in the lower end of tool 501 with frusto-conical configurations as shown in FIG. 5.

As previously indicated, the mortises and tenons of the workpieces to be joined by the use of the purposed method may be provided with circular or polygonal cross-sectional configurations, the recess of one of the workpieces may consist of a mortise, socket, dados, pocket mortise, slot or groove and the insertable portion of the other of such workpieces may consist, of a tenon, rabbet or tongue.

The use of the method as described permits the production of a set of component workpieces and the assembly of such workpieces into a final product as shown in FIG. 4 without the use of clamping devices as shown in FIG. 2. The cost of acquiring or producing and the inventorying of a number of clamps as shown in FIG. 2 is eliminated, and the time required in applying such clamping devices is avoided thus improving productivity in the process of producing products farmed of such workpieces.

The proposed method is particularly suited to the manufacture of wood products such as kitchen cabinets and furniture because of the composition of wood material which permits it to be readily machined to provide serrated side wall surfaces in which the projecting segments of such serrated side wall surfaces may be readily engaged by an inserted tenon or the like and deflected downwardly toward the bottom of the mortise in which the tenon is inserted to provide the interference fit between the workpieces, causing them to maintain their interrelationship, allowing an applied bonding agent to set and thus permanently secure such workpieces together.

From the foregoing detailed description, it will be evident that there are a number of changes, adaptations and modifications of the present invention, which come within the province of those persons having ordinary skill in the art to which the aforementioned invention pertains. However, it is intended that all such variations not departing from the spirit of the invention be considered as within the scope thereof as limited solely by the appended claims. 

1. A method of forming a joint between first and second workpieces, comprising: forming a recess in one of said workpieces, provided with at least one side wall having a serrated cross-sectional configuration with inwardly projecting, distortable segments; providing a portion in the other of said workpieces, insertable into said recess, having a cross-sectional configuration sufficient to engage and distort said segments as said portion is inserted into said recess; and inserting said portion of said other workpiece into said recess, causing said segments to distort and thus provide an interference fit between said workpieces.
 2. The method according to claim 1 including applying a bonding agent to one of said recess and said portion prior to insertion of said portion into said recess.
 3. The method according to claim 1 wherein said segments are provided with sloped surfaces enagageable by said portion inserted into said recess, causing said segments to deflect toward a bottom of said recess and thereby fix said portion within said recess.
 4. The method according to claim 1 including forming said recess with a circular cross-sectional configuration.
 5. The method according to claim 1 including forming said recess with a polygonal cross-sectional configuration.
 6. The method of claim 1 including forming said recess with a pair of opposed side walls each provided with a serrated cross-sectional configuration, and said insertable portion with a pair of outer side wall surfaces cooperable with serration segments of said opposed side all surfaces of said recess.
 7. The method of claim 1 including forming said recess as one of a group consisting of a mortise, socket, dados, pocket mortise, slot and groove, and forming said insertable portion as one of a group consisting of a tenor, rabbet and tongue.
 8. A product including at least first and second work pieces joined together at least partially by the method comprising: forming a recess in one of said workpieces, provided with at least one side wall having a serrated cross-sectional configuration with inwardly projecting, distortable segments; providing a portion of the other of said workpieces, insertable into said recess, having a cross-sectional configuration sufficient to engage and distort said segments as said portion is inserted into said recess; and inserting said portion of said other workpiece into said recess, causing said segments to distort and thus provide an interference fit between said workpieces.
 9. The product according to claim 8 including applying a bonding agent to one of said recess and said portion prior to insertion of said portion into said recess.
 10. The product according to claim 8 wherein said segments are provided with sloped surfaces enagageable by said portion inserted into said recess, causing said segments to deflect.
 11. The product according to claim 8 including forming said recess with a circular cross-section configuration.
 12. The product according to claim 8 wherein including forming said recess with a polygonal cross-sectional configuration.
 13. The product according to claim 8 including forming said recess with a pair of opposed side walls each provided with a serrated cross-sectional configuration, and said insertable portion with a pair of outer side wall surfaces cooperable with serration segments of said opposed side wall surfaces of said recess.
 14. The structure according to claim 8 including forming said recess as one of a group consisting of a mortise, socket, dados, pocket mortise, slot and groove, and forming said insertable portion as one of a group consisting of a tenor, rabbet and tongue.
 15. A tool for forming a serrated contour along a side wall surface of a recess in a workpiece, comprising an elongated body having an axis, mountable to a fastening means of a spindle for rotation about the axis thereof, provided with at least one annular recess in a side wall surface thereof, relative to said axis thereof, and arcuately spaced recesses in said side wall surface, relative to said axis thereof, cooperating with said annular recess to form cutting edges.
 16. A tool according to claim 15 wherein said annular recess is provided with a frusto-conically configured surface.
 17. A tool according to claim 15 including a plurality of said, annular recesses, providing a serrated cross-sectional configuration.
 18. A tool according to claim 17 wherein said annular recesses are provided with frusto-conically configured surfaces.
 19. A tool according to claim 15 wherein said arcuately spaced recesses in said side wall surface are diametrically displaced.
 20. A tool according to claim 15 wherein said arcuately spaced recesses extend the axial length of said annular recesses. 